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Development of Metal Matrix Composites suitable for hulls and ship decks
Author(s)
Muribwathoho, Oritonda
Date Issued
2025
Type
Thesis
Publisher
Cape Peninsula University of Technology
Abstract
Metal matrix composites (MMCs) have gained significant attention due to their enhanced
mechanical and tribological properties, making them suitable for various industrial
applications, particularly in the marine and aerospace sectors. However, challenges such as
poor reinforcement dispersion, porosity, and limited optimization of processing parameters
remain critical research gaps. While extensive studies have been conducted on aluminiumbased
MMCs, limited research exists on AA5083-H111 reinforced with coal, particularly in the
context of friction stir processing (FSP) as a fabrication method. This study aimed to fabricate
aluminium metal matrix composites (AMMCs) of AA5083-SiC and AA5083-Coal MMCs using
FSP for potential application in ship hulls and decks, focusing on reinforcing the joint region
rather than fabricating a bulk MMC sheet. The novelty of this research lies in the use of coal
as an alternative reinforcement, offering a cost-effective and sustainable approach to MMC
fabrication while maintaining high wear resistance and mechanical strength. Silicon carbide
(SiC) was used as a benchmark reinforcement due to its well-documented ability to improve
hardness, wear resistance, and thermal stability, providing a comparative reference for
evaluating the effectiveness of coal as a reinforcement material.
In the fabrication process, AA5083-H111 was reinforced with silicon carbide and coal particles
to create AMMCs, and their properties were compared to unreinforced AA5083-H111. To run
the test on the AA5083-H111, AA5083/SiC composite joints and AA5083/Coal composite
joints, the specimens were cut with a CNC milling machine. Among the tests performed were
tensile testing, macrostructure and microstructure analysis, fractographic analysis (SEM),
hardness tests, flexural tests, chemical composition analysis and X-ray diffraction (XRD)
analysis. The described specimens for the composites were cut from various positions on the
plates, including the plate's start, middle and end. This method enabled a thorough study of
material characteristics and behavior by constantly analyzing material properties at these
exact places across all testing. The following symbols were used to represent the cut positions
on the processed plates to symbolise their positioning (S for the start, M for the middle and E
for the end of the plate).
mechanical and tribological properties, making them suitable for various industrial
applications, particularly in the marine and aerospace sectors. However, challenges such as
poor reinforcement dispersion, porosity, and limited optimization of processing parameters
remain critical research gaps. While extensive studies have been conducted on aluminiumbased
MMCs, limited research exists on AA5083-H111 reinforced with coal, particularly in the
context of friction stir processing (FSP) as a fabrication method. This study aimed to fabricate
aluminium metal matrix composites (AMMCs) of AA5083-SiC and AA5083-Coal MMCs using
FSP for potential application in ship hulls and decks, focusing on reinforcing the joint region
rather than fabricating a bulk MMC sheet. The novelty of this research lies in the use of coal
as an alternative reinforcement, offering a cost-effective and sustainable approach to MMC
fabrication while maintaining high wear resistance and mechanical strength. Silicon carbide
(SiC) was used as a benchmark reinforcement due to its well-documented ability to improve
hardness, wear resistance, and thermal stability, providing a comparative reference for
evaluating the effectiveness of coal as a reinforcement material.
In the fabrication process, AA5083-H111 was reinforced with silicon carbide and coal particles
to create AMMCs, and their properties were compared to unreinforced AA5083-H111. To run
the test on the AA5083-H111, AA5083/SiC composite joints and AA5083/Coal composite
joints, the specimens were cut with a CNC milling machine. Among the tests performed were
tensile testing, macrostructure and microstructure analysis, fractographic analysis (SEM),
hardness tests, flexural tests, chemical composition analysis and X-ray diffraction (XRD)
analysis. The described specimens for the composites were cut from various positions on the
plates, including the plate's start, middle and end. This method enabled a thorough study of
material characteristics and behavior by constantly analyzing material properties at these
exact places across all testing. The following symbols were used to represent the cut positions
on the processed plates to symbolise their positioning (S for the start, M for the middle and E
for the end of the plate).
Additional information
Thesis (DEng (Mechanical Engineering))--Cape Peninsula University of Technology, 2025
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